Lightweight brake rotor and components with composite materials

ABSTRACT

A method including: placing a first insert and a second insert in a casting mold and wherein the first insert and second insert including a plurality of connecting posts extending in between so that the first insert and second insert are in spaced-apart relationship in the mold, each of the first insert and the second insert including a first material; casting a molten second material into the casting mold so that the second material flows between the first insert the second insert and solidifying the second material.

TECHNICAL FIELD

The field to which the disclosure generally relates includes methods of joining different materials and products made therefrom.

BACKGROUND

Vehicles that include wheels such as, but not limited to, automobiles, trucks, buses, airplanes and the like typically include braking systems. Such braking systems commonly include drum or disc brake rotors.

SUMMARY OF EXEMPLARY EMBODIMENTS

One embodiment of the invention includes a method comprising: placing a first insert and a second insert in a casting mold and wherein the first insert and second insert comprising a plurality of connecting posts extending in between so that the first insert and second insert are in spaced-apart relationship in the mold, each of the first insert and the second insert comprising a first material; casting a molten second material into the casting mold so that the second material flows between the first insert and the second insert and solidifying the second material to provide a product comprising a cast over body portion with the first insert and second insert and so that the second material is mechanically locked or metallurgically bonded to the first material and so that one or both of the first insert and the second insert provides working surface for the product.

Other exemplary embodiments of the invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while disclosing exemplary embodiments of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 illustrates a braking wheel useful in a method according to one embodiment of the invention.

FIG. 2 illustrates a vented disc brake rotor including a braking wheel and a cast over body portion including a hub according to one embodiment of the invention.

FIG. 3 illustrates an insert with projections having a trapezoidal shape useful in making an brake rotor according to one embodiment of the invention.

FIG. 4 illustrates a non-vented disc brake rotor including a braking wheel and a cast over body portion including a hub according to one embodiment of the invention.

FIG. 5 illustrates a braking wheel for a drum rotor useful in a method according to one embodiment of the invention.

FIG. 6 illustrates a drum rotor including a braking wheel and cast over body portion including a hub according to one embodiment of the invention.

FIG. 7 illustrates a sectioned core insert useful in making a disc brake rotor according to one embodiment of the invention.

FIG. 8 illustrates a sectional plan view of a sectioned casting core overlying a portion of a braking wheel including an annular disc and post extending therefrom and wherein the post received in slots formed in the casting core according to one embodiment of the invention.

FIG. 9 illustrates a method of making a disc brake rotor according to one embodiment of the invention.

FIG. 10 illustrates placing a first annular disc insert in a casting mold in a method of making a brake rotor according to one embodiment of the invention.

FIG. 11 illustrates a casting core including a plurality of channels formed therein for use in a method according to one embodiment of the invention.

FIG. 12 illustrates a method of placing the casting core of FIG. 10 in a casting mold according to one embodiment of the invention.

FIG. 13 illustrates an annular disc insert including locating features useful in a method according to one embodiment of the invention.

FIG. 14 illustrates a method of closing the casting mold and pouring molten material into the mold according to one embodiment of the invention.

FIG. 15 illustrates a vertical casting method including placing the first and second annular disc insert with locating feature in first and second mold halves respectively, and pouring molten material into the casting mold according to one embodiment of the invention.

FIG. 16 is a sectional, side view of an annular disc insert including a plurality of projections which may have a trapezoid-shape, L-shape or T-shape that is useful according to one embodiment of the invention.

FIG. 17A is a perspective view with portions broken away of a brake rotor with straight vanes according to one embodiment of the invention.

FIG. 17B is a perspective view with portions broken away of a brake rotor with pillar-type vanes according to another embodiment of the invention.

FIG. 17C is a perspective view with portions broken away of a brake rotor with straight, tangential vanes according to another embodiment of the invention.

FIG. 17D is a perspective view with portions broken away of a brake rotor with curved, tangential vanes according to another embodiment of the invention.

FIG. 18 is a sectional, side view of an annular insert including downwardly extending legs stamped out of the insert and useful in a method according to one embodiment of the invention.

FIG. 19 illustrates a sectional, side view of an annular insert including a tab stamped out of the insert including a downwardly extending leg portion and a foot useful in one embodiment of the invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The following description of the embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

Referring now to FIG. 1, one embodiment of the invention includes providing a braking wheel 10 which may include a first insert 12 and a second insert 14 which are maintained in spaced-apart relationship to each other by a plurality of posts 16 extending between the first insert 12 and the second insert 14. In one embodiment, the first insert 12, the second insert 14 and the posts 16 extending therebetween are cast from a single first material and are a continuous casting. The braking wheel 10 may be manufactured by casting, welding or other similar methods.

The braking wheel 10 may be utilized to make a disc brake rotor 18 shown in FIG. 2. The disc brake rotor 18 includes a cast over body 20 including a hub portion 22 and a second portion 24 extending between the first insert 12 and the second insert 14. The second portion 24 of the cast over body 20 may cover the insert annular inner surface and the outer circumferential surfaces of the inserts 12, 14. A plurality of vanes 26 or fins extending between the first insert 12 and the second insert 14 may define a plurality of vents 28 or channels therebetween to provide a vented brake rotor as shown in FIG. 2. The vanes 26 may be straight-shaped vanes, curved vanes, pillar-type vanes or any other type vane known to those skilled in the art. In one embodiment, each of the posts 16 of the brake wheel 10 may be surrounded by an associated vane 26 so that the cast over body 20 is mechanically locked to the brake wheel 10 or metallurgically bonded thereto at the post 16.

The braking wheel 10 may be made from a first material, such as cast iron to provide a first braking surface 34 on an outer face of the first insert 12 and a second braking surface 36 on an outer surface of the second insert 14. The cast over body 20 may be made of a second material that has a density and melting point less than that of the first material. In one embodiment of the invention the second material may include aluminum or alloy thereof. In one embodiment, all the exposed surfaces of the rotor comprise the second material except the two annular braking surfaces 34, 36 which comprise the first material. This arrangement prevents corrosion of the first material except at the exposed braking surfaces 34, 36. However, any corrosion at the exposed braking surfaces 34, 36 may be removed by the brake pads rubbing against the braking surfaces 34, 36.

Referring again to FIG. 1, in one embodiment, the post 16 and/or an inner surface 30 of the first insert 12 and/or an inner surface 32 of the second insert 14 may be treated, for example by applying a coating of graphite so that the inner surfaces 30, 32 and/or the posts 16 is wet by the molten second material and a metallurgical bond is formed between the cast over body portion and the inserts 12, 14 or post 16.

Referring now to FIG. 3, in one embodiment the first insert 12 (or the second insert 14) includes a plurality of trapezoid-shaped projections 16′ extending from an inner surface 30 of the first insert 12 (or an inner surface 32 of the second insert 14) thereof and wherein the second material is mechanically locked to the first material at the projections during a casting process. At least one of the outer surface 34 of the first insert 12 (or the outer surface 36 of the second insert 14) provides a first braking surface. Still other embodiment of annular disc inserts with projections 16′ are illustrates in FIGS. 16,18 and 19.

Referring now to FIG. 4, alternatively, the second portion 24 of the cast over body 20 may completely fill the space between the first insert 12 and the second insert 14 to provide a solid non-vented disc brake rotor 18.

Referring now to FIG. 5, in another embodiment of the invention, the brake wheel 10 may be constructed and arranged to form a cylindrical inner wall 14 with projections 16′ extending from an outer surface 36. In one embodiment the projection 16′ may have a trapezoid-shape, T-shape, L-shape, rectangular-shape and the like. Some examples of the designs for the projections 16′ are shown in FIG. 16. An inner face 32 of the cylindrical wall provides a braking surface.

Referring now to FIG. 6, the brake wheel 10 of FIG. 5 may be utilized to provide a cast over body 20 defining a hub portion 22 and a second portion 24 to completely cover all the projections 16′ on the braking wheel 10 to provide a drum brake rotor 18.

Referring now to FIG. 7, a casting core 42 may be utilized to make a vented disc brake rotor shown in FIG. 2. The casting core 42 may be a permanent metal core. In one embodiment the core 42 may be sectioned 45 into many pieces each of which may be slid between the first insert 12 and second insert 14 from a position associated with the outer diameter of the brake wheel 10 towards the center thereof. Each portion 44 of the core 42 may include at least one slot 46 formed therein having an open end 48 to receive the posts 16 extending between the first insert 12 and the second insert 14.

FIG. 8 is a sectional, planer view of a braking wheel 10 including a first insert 12 and a plurality of posts 16 extending upwardly therefrom and portions 44 of a core 42 overlying the first insert 12. During the casting operations, the slots 46 formed in each portion 44 of the core 42 will be filled with the second material to form vanes 26 extending between the first insert 12 and the second insert 14. The vane 26 may capture the posts 16 or projections 16′ and be mechanically locked thereto or the posts or projections may be treated so that the second material used to form the vane 26 is metallurgically bonded to the posts 16 or projections 16′. The core 42 may then be removed to leave vents 28 or channels between vanes 26.

Referring now to FIG. 9, one embodiment of the invention includes placing a braking wheel 10 and including a core 42 into at least one of a first portion 50 of a casting mold 49 or second portion 52 of a casting mold wherein the second portion 52 includes a projection 54 constructed and arranged to extend into the first portion 50 of a casting mold 49 to define the hub 22 of the brake rotor. The casting mold 49 may be a permanent metal mold. The material utilized for the braking wheel may be a first material such as cast iron and a second molten material 56 may be poured into the casting mold through a charge line 58. The second molten material 56 may be of a second material such as aluminum which has a lower melting point and is lighter than the first material. The casting mold 49 may include a vent 60 and other features known to those skilled in the art.

FIGS. 10-14 illustrate another embodiment of making a brake rotor. The first insert 12 may be a separate annular disc 12 with trapezoidal projections 16′ as shown in FIG. 16 and placed in the first portion of a casting mold 50. Thereafter, a casting core 42 may be placed over the first insert 12 (as shown in FIG. 12). The core 42 as shown in FIG. 11 may be a single intact piece including a plurality of channels 46 formed therein and constructed and arranged to produce vanes 26 during the casting process. FIG. 13 illustrates one embodiment of the invention in which the first insert 12 or the second insert 14 may include an annular disc portion 59 with locating features 106 on the braking surfaces 34, 36. As shown in FIG. 14, in one embodiment each of the first portion 50 and second portion 52 of the casting mold 49 may include the locating features 64 working together with the locating features 106 on the inserts to hold the inserts in place in the mold for casting. For example a plurality of recesses 64 formed therein to receive the locating features 106 so that each of the first insert 12 and second insert 14 may be held in a designed position. In another embodiment the second portion 52 of the casting mold 49 may include a magnet 104 to hold the second insert 14 and then be placed over the first portion 50 to close the mold 49, and the molten second material 56 may then be poured in through a charge line 58 to form a brake rotor having a cast over body 20 including a hub 22 and a second portion 24 (not shown) extending between the first insert 12 and the second insert 14. The locating features 106 on the first insert 12 and the second insert 14 may be machined off later. The locating features 106 may also be constructed to rest on the shoulder of a specially designed mold and may be clamped onto by the mold halves. To make a non-vented disc brake rotor the core 42 is not used.

Referring now to FIG. 15, in another embodiment each of the first insert 12 and second insert 14 may be held in a vertical position. Molten material 56 may be poured into the casting mold 49 to provide a rotor including a cast over body portion 20 including a hub portion 22 and a second portion 24 extending between the first insert 12 and the second insert 14, for example as shown in FIG. 4.

FIG. 16 illustrates one embodiment of a first insert 12 (or second insert 14) including a plurality of projections 16′ extending outwardly from a inner surface 30 of the first insert 12. The first insert 12 may include an outer first braking surface 34. The projections 16′ may be constructed and arranged so that a mechanical lock is provided when the second material is cast into the casting mold. The projections 16′ may have any of a variety of shapes. For example, the projection 16′ may be trapezoid-shaped, L-shaped, T-shaped or may have any shape providing a shoulder or surface against which the second material may be trapped and thereby preventing the first insert 12 (or second insert 14) from being pulled away from the second portion 24 of the cast over body 20.

FIG. 17A is a perspective view with portions broken away of a brake rotor according to one embodiment of the invention which includes straight vanes 26 with individual posts 16 trapped therein. FIG. 17B is a perspective view with portions broken away of a brake rotor according to another embodiment of the invention of a pillar-type design. FIG. 17C is a perspective view with portions broken away of a brake rotor according to another embodiment of the invention including tangential, straight aluminum vanes 26 with vane-shaped cast iron posts 16 trapped inside the aluminum vanes 26. FIG. 17D is a perspective view with portions broken away of a brake rotor according to another embodiment of the invention including tangential, curved aluminum vanes 26 with individual cast iron post 16 trapped inside the vanes 26.

FIG. 18 illustrates another embodiment of the invention including an insert 14 which includes a plurality of projections 16′ which may be formed by stamping a downwardly extending leg portion 68 out of the insert such as stainless steel or other material suitable for stamping.

As shown in FIG. 19, the projection 16′ may include a first bend 70 and second bend 72 therein to define a leg portion 68 and a foot portion 72 which may be substantially parallel to the main body portion 76 of the insert 14. In one embodiment, the projection 16′ may be stamped out of the main body portion 76 of the insert 14 at a location that is not in use.

Various embodiments of the invention may include any design features as that in traditional brake rotor designs, e.g., cross drilled holes or other machined features on the rotor surface, as well as coatings or heat treatment of rotor surfaces and the like. Various surface treatments may be performed on the first insert 12, second insert 14 and projections 16′ or posts 16 to improve the brake and/or rotor performance.

According to various illustrative embodiments of the invention, frictional damping may be achieved by the movement of the interfacing surfaces of the first material and the second material against each other.

One embodiment of the invention includes a product which may have a frictional damping means. In embodiments wherein at least a portion of at least one of inner faces 30, 32 of the inserts 12, 14 respectively, or the posts 16 may be coated with a material to product frictional damping. The coating may include fibers or particles that resist flowing when exposed to the temperature of a molten material such as in casting.

The above description of embodiments of the invention is merely exemplary in nature and, thus, variations thereof are not to be regarded as a departure from the spirit and scope of the invention. 

1. A method comprising: placing a first insert and a second insert in a casting mold so that the first insert and second insert are in spaced-apart relationship in the mold, each of the first insert and the second insert comprising a first material; casting a molten second material into the casting mold so that the second material flows between the first insert and the second insert and solidifying the second material to provide a product comprising a cast over body portion with the first insert and second insert, the cast over body portion comprising the second material and so that the second material is mechanically locked or metallurgically bonded to the first material and so that one or both of the first insert and the second insert provides working surface(s), further comprising a plurality of posts extending between and permanently connecting the first insert and the Second insert and wherein the second material surrounds each post and wherein the second material is mechanically locked to the first material at the posts, and wherein the posts extending between and connecting the inserts may be in the shape of round rods, rectangular bars, or curved fins, and wherein the first insert and the second insert and the plurality of posts are a single continuous workpiece, further comprising providing a sectioned annular casting core comprising a plurality of core sections, the core having slots formed therein each with an opened end, placing the core sections between the first insert and the second insert prior to casting, and wherein an associated post is received in the slot through the open end, and after the solidifying, removing the core to provide vanes extending between the first insert and the second insert where the slots in the casting core were and to provide vent channels between the vanes, and wherein a permanent mold and permanent core may be used to cast the second material.
 2. A method as set forth in claim 1 wherein each of the first insert and the second insert includes a plurality of projections extending from an inner face thereof, and wherein the second material is mechanically locked to the first material at the projections, and wherein the projection is trapezoid-shaped, T-shaped, L-shaped, or rectangular-shaped, and wherein the first insert or second insert and the projections are a single continuous workpiece.
 3. A method as set forth in claim 1 wherein the second material has a lower melting point, and a lower density if so designed, than that of the first material and wherein the examples of the first material are cast iron, steel, and ceramic composite and the examples, of the second material are aluminum alloy and cast steel.
 4. A method as set forth in claim 1 wherein the first insert comprises a first annular brake disc and wherein the second insert comprises a second annular brake disc and wherein the second material comprises-a hub and a cast over body portion extending between the first insert and the second insert and wherein the brake rotor is a disc brake rotor and wherein the first braking surface is provided by an outer surface of the first insert, and further comprising a second braking surface provided by an outer surface of the second insert, and wherein the brake rotor is either solid or vented.
 5. A method comprising: placing at least a first insert in a casting mold so that the first insert comprising a, plurality of projections extending from first surface thereof and the first insert comprising a second surface, the second surface providing a working surface; the first insert comprising a first material; casting a molten second material into the casting Mold so that the second material provides a cast over body portion comprising the second material and so that the second material is mechanically locked to the plurality of projections and solidifying the second material to provide a drum brake rotor and wherein the first insert comprises a cylindrical wall with projections extending from an outer surface of the cylinder wall and wherein the brake surface is provided by an inner wall of the cylindrical wall, further comprising providing a coating on an inner surface of the first insert to provide frictional damping, and the coating comprising fibers or particles that resist flowing when exposed to the temperature of a molten second material. 